Team FOAM Design Team 6

1. Team FOAMDesign Team 6 Advisor: Dr. Darrel Doman Client: Precise Designs Engineering Solutions Members: Fredrik Sy, DainisNams, Allison Chua, MotazTaha

2. Contents Background Requirements Initial Testing Design Alternatives Final Design Selection Prototype Future Work

3. Background Polyplank foam (www.casecad.com) • Client’s production requires foam profile cutting • Current method is water jet cutting: • Outsourced • Long drying time • Client wants to cut foam using in house machine shop

4. Essential Requirements • Safety • Interface with CNC machine head • Arbitrary pocket profiles • Minimum hole dimension of 1/4 in. • Cut depth of 4.75 in. • Acceptable cut quality • Minimal need for replacing or cleaning parts

5. Important Requirements • $3,000 budget • Ease of installation and detachment from CNC machine • Acceptable cut speed • Cut tolerance of 1/32 in. • Body not longer than 6 in.

6. Current Methods • 4 Axis CNC Wire Foam Cutter • (www.hotwiredirect.com) • Die Cutter • (www.chiyodaintegreusa.com) Water Jet Cutting (http://www.aqua-dynamics.co.uk)

7. Project Idea • Heated bit cutter • Fluted bit versus round bit • Temperature range to produce acceptable cut quality • Rotation versus no rotation • Knife cutter • 1/4 in. holes • Corners

8. Heated Rod Testing Performing Foam Cuts With Round Bit Thermally Insulating The Bit Measuring Oven Temperature • Experimental setup: • Fluted and round bits • Standard drill press • Oven: controlled temperature

9. Heated Rod Testing Results • Poor Cut Quality • Good Cut Quality • Uneven Cut Quality • Results: • Round bits perform better cut quality • Temperature range required: 180-200˚C • Rotation is required

10. Knife Cutter Testing Knife Prototype • Constructed a prototype of thin blade cutter • Results: • Excellent cut quality • Difficult to follow tight corners

11. Design Alternatives Body And CAT40 Mounting Rotational Power Transfer Cutting Element Holder Cutting Element • Four Subsystems • Design divided into subsystems: • Cutting element • Cutting element holder • Rotational power transfer • Body and CAT40 mounting

12. Cutting Element 2. Thick Cutting Element 1. Thin Cutting Element Two main alternatives generated:

13. Cutting Element Holder 1. Standard, Off-The-Shelf Chuck 2. Standard, Off-The-Shelf Collet 3. Insulated Set Screw Holder Three main alternatives generated:

14. Rotational Power Supply Attachment 1. Magnetic Attachment 2. Bracket Attachment Rotational power supply through slip ring Two main alternatives for attachment of slip ring:

15. Body And CAT40 Mounting Generic CAT40 With Custom Body 1. Integrated CAT40 Collet Holder Two main alternatives generated:

16. Final Design CNC Machine Head Bracket Attachment CAT40 Head Slip Ring Collet Holder Thick Cutting Element Final Design

17. Design Project Status Slip Ring Wires PVC Tube Contact With Resistance Wire Cutting Element Slip ring prototype • Slip ring prototype • >10 Amps • Thick cutting element prototype • Can cut foam

18. Cut Quality Cut Surface Cut Surface Team FOAM Cut Foam Water Jet Cut Foam Comparable cut quality

19. Future Work • Further Prototyping • Cutting Element • Temperature Regulation • Ordering Components • Final Design Construction

20. Acknowledgements Project Supervisor: Dr. Darrel Doman Design Project Course Coordinator: Dr. Andrew Warkentin Dalhousie Technician: Angus MacPherson Shell SolidWorks ROV Team Client: Precise Designs Engineering Solutions

21. Safety Regulations (1) Purpose: The purpose of this document is to outline the safety procedures to be followed for any testing to be done in the TEAM FOAM project and specifies the responsibilities of the individuals performing said testing or experiment. The document also outlines requirements in the procedures of these experiments and testing. General Safety Procedure: This section applies to all testing. Any testing done with heating elements, electrical devices or any device that may bring bodily harm requires the presence of at least two people performing the experiment. Each person is responsible for both himself/herself and for every other person performing the testing to abide by the safety procedure outlined in this document. Should one person be injured or incapacitated, it is the responsibility of the all the members performing the test to ensure that immediate and proper treatment be applied

22. Safety Regulations (2) • Heating elements: • This section pertains to all testing done with any heating elements. The following safety equipment/procedures must be used: • Safety Glasses • Gloves with thermal insulation sufficient for the temperatures of the experiment • No open toe footwear • The heating element must be at least 5 feet away from any easily combustible fuel • The heating element must not rest or be held in place with chance of heating element igniting any object.

23. Safety Regulations (3) • Electrical power supplies: • This section pertains to constructing electrical circuitry or mechanism that convey/interact in some way that are not inherently electrically insulated. The following safety equipment/procedures must be used: • Safety Glasses • Gloves with electrical insulation • The electrical equipment must be at least 5 feet away from any easily combustible fuel so as to avoid the chance that a spark ignites the fuel. • The testing mechanism must be designed such that the mechanism cannot draw power unless the person using the mechanism is not at least 3 feet away from the equipment.

24. Thermal Imaging Results Heating Source Thin Rod Heated Thin Blade Very poor temperature gradient in thin element heated at top

25. Thermal Imaging results (2) Chuck Cool Top Uniform Heat Distribution Heated Oven Element Uniform Heat Distribution (resistance wire in core)

26. Knife Cutter Testing Thin Knife Blade Freely Spinning Joint

27. Knife Cutter Testing Cut Surface Corner Cuts:

28. Budget